Maintenance-free bearing with tolerance compensation properties against wear and misalignment

ABSTRACT

A system for elastically compensating for wear, thermal expansion and misalignment comprises a ring located between a housing and a pin in the bore of the housing. The ring has a backing layer, an expanded grid structure having a plurality of openings, a low friction layer penetrated into the openings of the expanded grid structure, and adhesive for bonding the backing layer, expanded grid structure and low friction layer together to provide elastic deformation of the ring between the housing and pin.

This application claims priority to and the benefit of U.S. ProvisionalPat. App. No. 61/296,065, filed Jan. 19, 2010, which is incorporatedherein by reference in its entirety.

BACKGROUND

Field of the Disclosure

The invention relates in general to bearings and tolerance rings and, inparticular, to an improved system, method and apparatus for amaintenance-free bearing assembly with tolerance compensation propertiesagainst wear and misalignment.

Description of the Related Art

Bearings and tolerance rings constrain movement between parts that moverelative to each other, such as rotating shafts in housing bores. Anexample of such a structure is an annular band located in the gapbetween the outer surface of a shaft and the inner surface of a bore.This tolerance ring limits radial or axial motion of the shaft withinthe bore while still permitting relative movement.

In conventional designs, a close fit is sought between the inner andouter components. In addition, either forces for providing maximalfrictional engagement or minimal variation in sliding forces are sought.A close fit between the components is desirable because it reducesrelative vibration between the parts. Tolerance rings are able tocompensate for tolerances or misalignments, create torque and canimprove other properties, such as noise, vibration and harshnessproperties. Such properties and torque are mainly influenced by thematerial properties of common tolerance rings, which are usually formedonly from stainless or carbon steel. These requirements between theinner and outer components require strong and substantial contact, whichincreases frictional forces.

For example, a conventional bushing 31 (FIG. 3A) comprising a backinglayer 33 and plastic compound 35 is located between a pin 37 and housing39. When a significant force F (exaggerated in FIG. 3B) is applied tothe pin 37, the bushing 31 is deformed and excessively worn, andundesirable contact or uneven friction occurs between the pin 37 andbacking layer 33. Although these solutions are workable for someapplications, improvements in bearings and tolerance rings continue tobe of interest.

SUMMARY OF THE INVENTION

Embodiments of a system, method and apparatus for bearings and tolerancerings for a maintenance-free assembly with tolerance compensationproperties against wear and misalignment are disclosed. For example, asystem for elastically compensating for wear, thermal expansion andmisalignment comprises a ring located between a housing and a pin in thebore of the housing. The ring has a backing layer, an expanded gridstructure having a plurality of openings, a low friction layerpenetrated into the openings of the expanded grid structure, and mayadditionally comprise one layer of adhesive for bonding the backinglayer and/or a second layer of adhesive for bonding the low frictionlayer to the expanded grid. Together, the expanded grid structure andthe low friction layer provide elastic deformation of the ring betweenthe housing and pin.

The expanded grid structure may comprise a stretched metal, expandedmetal, metal alloy or plastic material, or a woven or nonwoven mesh. Thelow friction layer is laminated into the expanded grid structure. Inaddition, the expanded grid structure may have a wave-like configurationwith strands protruding as bulges out of a plane thereof to form apattern of waves and bow springs to provide elastic deformation underload. The expanded grid structure may be completely or only partiallyembedded into the low friction layer such that portions of the expandedgrid structure protrude from the low friction layer and contact the pin.

The ring provides sliding properties and tolerance compensation forproduction tolerances, clearance tolerances, torque tolerances, materialdifferences, temperature differences, load variation, dynamic behavior,and wear between components. The ring further provides at least one ofradial and axial elastic deformation. When a force is applied to thepin, the expanded grid structure compresses in some areas and expands inother areas to compensate for wear and misalignment around a completecircumference of the ring.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerousfeatures and advantages made apparent to those skilled in the art byreferencing the accompanying drawings.

FIGS. 1A and B are exploded and assembled sectional side views,respectively, of one embodiment of a laminate material;

FIGS. 2A and B are sectional side views of embodiments of bushingsconstructed from the laminate of FIGS. 1A and B;

FIGS. 3A and B are sectional side views of a conventional bushing inoperation;

FIGS. 4A and B are sectional side views of the embodiment of FIG. 2B inoperation;

FIG. 5 is a magnified top view image of a grid structure;

FIG. 6 is a sectional side view of another embodiment of a laminate;

FIG. 7 is a sectional side view of still another embodiment of alaminate;

FIG. 8 is a sectional side view of a different embodiment of a laminate;

FIGS. 9A-C are sequential sectional side views of the laminateembodiment of FIG. 8 during operation;

FIGS. 10A-C are sequential sectional side views of the embodiment ofFIG. 8 during another type of operation;

FIGS. 11-13 are plots of load and unload cycles for various embodimentsof bearing components; and

FIGS. 14A-C are sequential sectional side views of the embodiment ofFIG. 8 during another type of operation.

The use of the same reference symbols in different drawings indicatessimilar or identical items.

DETAILED DESCRIPTION

Embodiments of a system, method and apparatus for bearings and tolerancerings for a maintenance-free ring assembly with tolerance compensationproperties against wear and misalignment are disclosed. For example,FIGS. 1A and B depict a laminate for a bearing or tolerance ringassembly 21 having a backing layer 23, an expanded grid structure 25 anda low friction layer 27, such as a tape. Depending on laminate set up,material layers of melt adhesive 29 may be located between thesecomponents to bond them together. During assembly, the low frictionlayer 27 penetrates the expanded grid structure 25, as shown in FIG. 1B.In some embodiments, the laminate may be formed into a ring with the lowfriction layer 27 facing radially outward (FIG. 2A) or inward (FIG. 2B).

In other embodiments, one of the layers of the melt adhesives 29 (FIG.1A) may be omitted, provided the other one penetrates through theexpanded grid structure 25 and immerses both sides of the expanded gridstructure so as to induce adhesion on both sides (i.e., grid structure25 to both tape 27 and backing layer 23).

In still other embodiments, both melt adhesive layers 29 (FIG. 1A,without layers 29) may be omitted, provided adhesion of the low frictionlayer to the expanded grid (and/or to the backing material) and adhesionfrom the expanded grid to the backing material is ensured by alternatemeans.

In some embodiments, the backing layer 23 is steel, stainless steel, aplain steel alloy, or another metal alloy and has a thickness in a rangeof about 0.01 mm to 5 mm. The grid structure 25 may be formed fromstainless steel, spring steel, aluminum, bronze or other metal alloys,thermoplastic or ceramic material, and has a thickness in a range ofabout 0.05 mm to 2 mm. The low friction layer 27 may comprise a plasticcompound layer, such as PTFE or other materials as described herein, andmay contain organic, inorganic, metallic or plastic fillers. The lowfriction layer may be laminated on top of and embedded into the gridstructure, and has a thickness in a range of about 0.01 mm to 1 mm.

In still other embodiments, the low friction layer 27 may comprisematerials including, for example, a polymer, such as a polyketone,polyaramid, a thermoplastic polyimide, a polyetherimide, a polyphenylenesulfide, a polyethersulfone, a polysulfone, a polyphenylene sulfone, apolyamideimide, ultra high molecular weight polyethylene, afluoropolymer, a polyamide, a polybenzimidazole, or any combinationthereof. In an example, the thermoplastic material includes apolyketone, a polyaramid, a polyimide, a polyetherimide, apolyamideimide, a polyphenylene sulfide, a polyphenylene sulfone, afluoropolymer, a polybenzimidazole, a derivation thereof, or acombination thereof. In a particular example, the thermoplastic materialincludes a polymer, such as a polyketone, a thermoplastic polyimide, apolyetherimide, a polyphenylene sulfide, a polyether sulfone, apolysulfone, a polyamideimide, a derivative thereof, or a combinationthereof. In a further example, the material includes polyketone, such aspolyether ether ketone (PEEK), polyether ketone, polyether ketoneketone, polyether ketone ether ketone, a derivative thereof, or acombination thereof. An example fluoropolymer includes fluorinatedethylene propylene (FEP), PTFE, polyvinylidene fluoride (PVDF),perfluoroalkoxy (PFA), a terpolymer of tetrafluoroethylene,hexafluoropropylene, and vinylidene fluoride (THV),polychlorotrifluoroethylene (PCTFE), ethylene tetrafluoroethylenecopolymer (ETFE), ethylene chlorotrifluoroethylene copolymer (ECTFE), orany combination thereof. In an additional example, the thermoplasticpolymer may be ultra high molecular weight polyethylene.

Lubrication of the sliding surface may be used in high forceapplications. Exemplary lubricants may include oil, grease, or solidlubricants such as molybdenum disulfide, tungsten disulfide, graphite,graphene, expanded graphite, boron nitride, talc, calcium fluoride,cerium fluoride, or any combination thereof. An exemplary ceramic ormineral includes alumina, silica, titanium dioxide, calcium fluoride,boron nitride, mica, Wollastonite, silicon carbide, silicon nitride,zirconia, carbon black, pigments, or any combination thereof.

The performance of the bearing material also is affected by selection ofthe parameters of the three-dimensional, expanded grid structure 25. Thegrid structure 25 can be a stretched or expanded metal, metal alloy(e.g., spring steel) or plastic material, or a woven or nonwoven mesh(e.g., with welded contact points like Norglide® M) or any other wovenor nonwoven net, grid or mesh structure with compensating properties.This structure has defined geometry and mechanical properties. The gridstructure is embedded in a plastic material, such as PTFE by laminating,spraying or calendaring and sintering (or any other method for applyingplastic material to the grid structure) on and/or around the gridstructure.

A number of parameters of the grid structure may be selected andadjusted based on the application. The parameters include thethree-dimensional structure of the expanded grid, the material it isformed from, and the backing and design of grid with respect to thesubstrate (if metal or other material backed) or to the housing. Theprocessing into an expanded grid involves cutting of the raw materialsheet and deforming or pulling the resulting grid. Because the cutstrands of the sheet are torn during processing, the single strands ofthe grid twist and form bulges in every row of the expanded grid, andthen protrude perpendicularly out of a plane defined by the expandedgrid. The bulges form a three-dimensional structure together with thetwo-dimensional expanded grid mesh geometry.

In alternate embodiments, a structure similar in function to an expandedgrid structure may be produced by a variety of other processes, such asextrusion, encapsulation, three-dimensional printing, etc., which may bemore costly than the cutting and expansion process.

In some embodiments (see, e.g., FIG. 5), the three-dimensional structure25 has a wave-like appearance. The strands 51 protrude as bulges 53 outof the plane of the sheet form waves and appear like bow springs 55while providing for an elastic and plastic behavior of the entirelaminate. Accordingly, the laminate can be used in situations where aspring-like behavior is desired over a very short distance (i.e., smalldeformations of the laminate), or in situations where tolerances need tobe compensated.

In some applications the deformation may be characterized in terms of apercentage of the diameter of the bearing or tolerance ring. Forexample, for a bearing having a 10 mm diameter, the low friction layermay compensate for about 5 to 20μ of elastic deformation, and up toabout 0.1 to 0.2 mm of compensation for the overall assembly with thegrid structure for 100% elastic recovery. This design is particularlyuseful for applications such as bushings formed from the laminate.

A ring formed with a PTFE-compound laminate in accordance with someembodiments of the invention, compensates for tolerances in workmanshipor application between a housing and shaft assembly, particularlybetween the bearing surface and the shaft. The bushing then not onlyprovides gliding and/or sliding properties to the assembly, but alsotolerance compensation regarding production tolerances, clearancetolerances, torque tolerances, material or temperature differences, loadvariation or dynamic behavior, aging or wear between assemblies parts,or any combination of these.

The compensation primarily occurs in the radial direction but is not solimited, as axial compensation also may be provided. For example, if thebushing has an additional flange, tolerance compensation can also beprovided in axial direction with the main working principles being thesame as in the radial case.

Depending on the clearance, the laminate of the bushing is compressed toa certain degree during assembly or application, and stays in this formthroughout the life of the assembly or application. Should the toleranceof the assembly change over time (e.g., through deformation of thehousing), then the elastic portion of the behavior of the laminateaccommodates such changes.

For example, comparing FIGS. 4A and 4B, bushing 21 is located in a borebetween a coaxial pin 41 and housing 43. Applying force F to the pin 41causes the expanded grid structure 25 to compress in some areas 45(i.e., opposite force F, and shown exaggerated for clarity), and expandin other areas 47 to better compensate for wear and misalignment.

The tolerance compensating material has several functional movements.These include compensation of tolerances, acting under load as a spring,compensation of thickness variations due to temperature differences orthickness changes (e.g., due to wear during application; see, e.g.,FIGS. 9A-C) or compensation of torque differences.

To achieve these compensations, the laminate and tolerance compensatingmaterial may be designed in many ways. The grid structure may be partlyembedded into the low friction material. Along with the low frictionmaterial, the peaks or other portions of the grid structure may protrudefrom the embedding material and contact the shaft in application orafter assembly, whether or not under load. Alternatively or incombination, other peaks or portions of the grid structure may contactthe backing material or housing without completely engaging the entiresurface of the backing material or housing.

The material can be compressed with such compositions. During embedding,the embedding material moves into volumes of the grid structure wherethere is no grid structure, such as voids, air bubbles or where there isa softer, more compressible material than the expanded grid.

In other embodiments, the grid structure may be completely embedded inthe low friction material and has complete contact with the backingmaterial or housing. In this case the grid structure is compressed whilestaying embedded completely. The entire composite of grid andsurrounding low friction material is deformed and relaxes afterunloading completely or partially.

The plastic and elastic part of the behavior of the laminate can betailored by several parameters. For example, performance is affected bymaterial selection of the expanded grid material, low friction layer andfiller types, as well as the backing material. The backing material alsomay comprise several alloys or represent a material composite. Therespective thicknesses of the expanded grid structure, backing materialand plastic compound also affect performance.

In addition and again as shown in FIG. 5, other dimensions may beselected such as long way of the diamond (LWD; or horizontal distancebetween reference points in the same row) and short way of the diamond(SWD; or vertical distance between reference points in the same column)in the geometric, two-dimensional parameters of the expanded gridstructure. Reducing the thickness of the expanded grid by flattening itincreases its stiffness in the out-of-plane direction. Other variablesinclude selection of horizontal and vertical in-plane distance betweenadjacent structural openings, such as mesh opening, knot width (KW) andstrand width (SW) versus LWD/SWD, long way of opening (LWO), short wayof opening (SWO) as well as selection of the direction in which theexpanded grid is laminated into the laminate and eventually deployed.

In some embodiments, a stiffer laminate may be formed by reducing therelation of transverse mesh opening to LWD, and/or the longitudinal meshopening to SWD. Other options include increasing the strand thicknessand/or knot width, flattening the expanded grid, increasing the rawmaterial sheet thickness, and/or increasing the expanded grid materialhardness and/or tensile strength.

FIG. 6 depicts another embodiment of laminate assembly 61 for bushingsand tolerance rings. Assembly 61 has a backing layer 63, grid structure65 and low friction layer 67. The low friction layer 67 fullyencapsulates the grid structure 65 and is bonded to backing layer 63. Inthis embodiment, the low friction layer 67 has smooth surfaces with noadditional structure. The grid structure 65 comprises a large pluralityof concave features 69 that can be compressed under load, providingsemi-elastic behavior in radial and/or axial directions of a bushing.

FIG. 7 depicts still another embodiment of a laminate assembly 71 havinga backing layer 73, grid structure 75 and low friction layer 77. The lowfriction layer 77 encapsulates the grid structure 75 and is bonded tobacking layer 73. In this embodiment, the low friction layer 77 has anundulated surface with recesses 79 that align with and are complementaryto the concave elements of grid structure 75, but which face away frombacking layer 73.

An inverted version of the prior embodiment appears in FIG. 8, whereinthe recesses 89 and concave elements of grid structure 85 face towardthe backing layer 83 of laminate assembly 81 to form air pockets orvoids therebetween. Both grid structures 75, 85 and the recesses 79, 89can be compressed under load volume, in radial and/or axial directions,to provide elastic behavior in operation and readily compensate for wearand misalignment.

For example, FIG. 9A illustrates assembly 81 unloaded as a bearing ortolerance ring and at an original dimension or thickness. In FIG. 9B,the bearing or tolerance ring wears under load 91 and sliding speed 93,causing a reduction in the thickness of low friction layer 87, as shown.However, the bearing or tolerance ring is self-adjusting (FIG. 9C)during the application as grid structure 85 compensates for wear byreturning the assembly to the original dimension as in FIG. 9A.

Analogously, FIG. 10A illustrates assembly 81 unloaded as a bearing ortolerance ring. In FIG. 10B, the bearing or tolerance ring is under load101, causing the grid structure 85 and recesses 89 of low friction layer87 to deform, as shown. The bearing or tolerance ring is self-adjusting(FIG. 10C) during the application as assembly 81 compensates for thedeformation and returns to the original dimension as in FIG. 10A. Load101 may represent the elevated thermal expansion (or contraction) of theshaft and/or housing, in which case the assembly compresses and thenreturns to its original thickness after cooling to ambient temperatures.

Similarly, FIG. 14B represents the application of a misaligned load 111to assembly 81, and the structure before (FIG. 14A) and after (FIG. 14C)application of misaligned load 111. During application of the misalignedload 111 (FIG. 14B), the volumes or holes in the structure arecompressed and the grid acts as a spring locally (i.e., on one side ofthe bearing/tolerance ring as represented by the dashed line. Afterrelaxation (FIG. 14C), the bearing material relaxes and the thicknesslocally returns to the original level.

The grid structure 85 may be configured such that the peaks of thestructure are deformed from the original position (FIG. 10A) underpressure 101 (FIG. 10B) in different bearing applications, and return totheir original position (FIG. 10C) after relaxation or after removal ofthe load 101.

In force-elongation diagrams (see, e.g., FIGS. 11-13) there is almost noplastic deformation exhibited inside a typical range of loads anddeformation for tolerance rings or sliding bearings. This fully elasticbehavior also permits adjustment of the bearing or tolerance ring,although the functional surface does wear during its life time of use.Throughout its life time, the surface of the functional layer alwaysremains at the same position. For example, the inner diameter of abearing or tolerance ring is constant over its life time and under allapplication conditions.

In other embodiments, the geometry of the expanded structure isconfigured such that the peaks do not return to their original position(i.e., they plastically deform) but overall the ring assembly stillmaintains elastic behavior. This design may be used for tolerancecompensation during the life time of a ring assembly or during thesizing procedure after its manufacture.

Referring again to FIGS. 11-13, the elastic and plastic behavior of thelaminate under an applied load is depicted. These illustrate anexemplary load appearing in, for example, a maintenance-free automotivebearing application. In FIG. 11, two typical loading/unloading cycles1101, 1103 are measured with increasing/decreasing pressure on anexpanded bronze grid and on a laminate, respectively, containing thesame expanded grid structure. The bare expanded bronze grid yields ahigher resulting deformation (i.e., deformation difference between startof loading cycle and end of unloading cycle) than the laminate. Thisdifference results from the forces during lamination, which pre-compressthe expanded bronze grid so that the laminate has a lower overalldeformation when subjected to the same pressure conditions. Arrowsfacing upwards or to the right represent the loading phase, arrowsfacing downwards or to the left represent the unloading phase. Themaximum applied load in these tests was 157.5 N/mm². Likewise, the plots1201 and 1301 in FIGS. 12 and 13, respectively, illustrate elasticbehavior for both hard spring and soft spring requirements.

In some embodiments, the invention comprises a system for elasticallycompensating for wear and misalignment. A ring such as a bushing,bearing or tolerance ring is located between the housing and pin in thebore of the housing. The ring comprises a backing layer, an expandedgrid structure having a plurality of openings, a low friction layerpenetrated into the openings of the expanded grid structure, and atleast one layer of adhesive for bonding the backing layer, expanded gridstructure and low friction layer together to provide elastic deformationof the ring between the housing and pin. The at least one layer ofadhesive may comprise a pair of layers of melt adhesive that penetratethrough the expanded grid structure and immerse sides of the expandedgrid structure to both the backing layer and the low friction layer.

In other embodiments, the backing layer may comprise one of steel,stainless steel and a plain steel alloy, and has a thickness in a rangeof 0.01 mm to 5 mm, the grid structure may comprise one of stainlesssteel, spring steel, aluminum, bronze, thermoplastic and ceramicmaterial, and has a thickness in a range of 0.05 mm to 2 mm. The lowfriction layer may comprise a plastic compound with organic, inorganic,metallic or plastic fillers, and has a thickness in a range of 0.01 mmto 1 mm.

The expanded grid structure may comprise at least one of a stretchedmetal, expanded metal, metal alloy and plastic material, and the lowfriction layer is laminated into the expanded grid structure. Theexpanded grid structure also may comprise a cut raw material sheethaving rows that are deformed with cut strands that are twisted and formbulges in every row. The bulges protrude out of a plane defined by theexpanded grid structure.

In addition, the expanded grid structure may have a wave-likeconfiguration with strands protruding as bulges out of a plane thereofto form a pattern of waves and bow springs to provide elasticdeformation under load. The expanded grid structure may be completely oronly partially embedded into the low friction layer such that portionsof the expanded grid structure protrude from the low friction layer andcontact the pin. The elastic deformation may be characterized in termsof a percentage of a diameter of the ring, and the ring is a split ring.For example, for a ring having a 10 mm diameter, the low friction layercompensates for 5 to 20μ of elastic deformation, and overall the ringcompensates for 0.1 to 0.2 mm of elastic deformation.

The ring provides sliding properties and tolerance compensation forproduction tolerances, clearance tolerances, torque tolerances, materialdifferences, temperature differences, load variation, dynamic behavior,and wear between components. The ring further provides at least one ofradial and axial elastic deformation. When a force is applied to thepin, the expanded grid structure compresses in some areas and expands inother areas to compensate for wear and misalignment around a completecircumference of the ring.

In some embodiments, a geometry of the expanded grid structure isselected and patterned by dimensions of the openings with long way ofthe diamond (LWD), short way of the diamond (SWD), thickness, horizontaland vertical in-plane distance between adjacent openings, mesh openings,knot width and strand width versus LWD/SWD, thickness of a single strand(TSS; material thickness before expansion), total grid thickness (TGT;material thickness after expansion), and selection of a direction inwhich the expanded grid structure is laminated and deployed.

The ring may be made stiffer by reducing a relation of transverse meshopening to LWD, longitudinal mesh opening to SWD, increasing a strandthickness or knot width, flattening the expanded grid structure,increasing a thickness of a raw material sheet, and increasing ahardness or tensile strength of the expanded grid structure.

The low friction layer may be provided with smooth surfaces with noadditional structure, and the expanded grid structure comprises aplurality of concave features that are compressible under load.Alternatively, the low friction layer may have an undulated surface withrecesses that align with and are complementary to concave elements ofthe expanded grid structure. The recesses may face away from or towardthe backing layer, and both the expanded grid structure and the recessesare compressible under load to provide elastic behavior in operation andcompensate for wear and misalignment.

In some versions, the ring has an original thickness, the ring deformsunder load causing the expanded grid structure and recesses in the lowfriction layer to deform, and the ring self-adjusts to elasticallycompensate for the deformation and return the ring to the originalthickness. In other versions, the ring has an original thickness, thering wears under load and sliding speed between the housing and pin toreduce a thickness of the low friction layer, and the expanded gridstructure self-adjusts to elastically compensate for the wear to returnthe ring to the original thickness.

The embodiments disclosed herein have numerous advantages overconventional solutions. These bearings and tolerance rings aremaintenance-free and have tolerance compensation properties againstmisalignment. They are also self-adjusting in the event of wear duringoperation and application. The bearing material also springs back to itsoriginal dimensions because of its tolerance compensating properties.These embodiments also compensate for tolerances due to temperaturedifferences, and provide bushings for shafts and components with widertolerances, which reduce the cost of manufacturing.

The encapsulated grid structure or stretched metal sheet uses the springbehavior of grid design and material to compensate for tolerances or, ingeneral, radial or axial distances in tolerance ring and bearingapplications with fully elastic behavior that enables a self-adjustingfunction. The assembly is well suited for use as a tolerance ring withsliding properties, or as a sliding bearing with elastictolerance/distance compensating functions in radial and/or axialdirections. The design is self-adjusting when the bearing wears out.

In addition, the invention compensates for the disadvantages ofconventional bearing or tolerance ring properties. For bearings, theinvention compensates for tolerances originating from production of thebearing, housing and shaft, thickness variations originating fromtemperature differences in the application, and wear or deformation bydynamic effects such as changing loads in an application.

For tolerance rings, the invention increases useful life by providingbetter sliding properties with compounds that generate lower frictionvalues between the shaft and tolerance ring, lower movement forcesbecause of lower friction, and a higher number of life cycles because oflower wear between the tolerance ring, shaft and housing. Otheradvantages include elastic compensation of distances in bearing andtolerance ring applications since the bearing acts like a spring, andthe tolerance ring acts like a bearing.

This written description uses examples to disclose the embodiments,including the best mode, and also to enable those of ordinary skill inthe art to make and use the embodiments. The patentable scope is definedby the claims, and may include other examples that occur to thoseskilled in the art. Such other examples are intended to be within thescope of the claims if they have structural elements that do not differfrom the literal language of the claims, or if they include equivalentstructural elements with insubstantial differences from the literallanguages of the claims.

Note that not all of the activities described above in the generaldescription or the examples are required, that a portion of a specificactivity may not be required, and that one or more further activitiesmay be performed in addition to those described. The order in whichactivities are listed are not necessarily the order in which they areperformed.

In the foregoing specification, the concepts have been described withreference to specific embodiments. However, one of ordinary skill in theart appreciates that various modifications and changes can be madewithout departing from the scope of the embodiments as set forth in theclaims below. Accordingly, the specification and figures are to beregarded in an illustrative rather than a restrictive sense, and allsuch modifications are intended to be included within the scope of theembodiments.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,method, article, or apparatus that comprises a list of features is notnecessarily limited only to those features but may include otherfeatures not expressly listed or inherent to such process, method,article, or apparatus. Further, unless expressly stated to the contrary,“or” refers to an inclusive-or and not to an exclusive-or. For example,a condition A or B is satisfied by any one of the following: A is true(or present) and B is false (or not present), A is false (or notpresent) and B is true (or present), and both A and B are true (orpresent).

Also, the use of “a” or “an” are employed to describe elements andcomponents described herein. This is done merely for convenience and togive a general sense of scope. This description should be read toinclude one or at least one and the singular also includes the pluralunless it is obvious that it is meant otherwise.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

After reading the specification, skilled artisans will appreciate thatcertain features are, for clarity, described herein in the context ofseparate embodiments, may also be provided in combination in a singleembodiment. Conversely, various features that are, for brevity,described in the context of a single embodiment, may also be providedseparately or in any subcombination. Further, references to valuesstated in ranges include each and every value within that range.

1-32. (canceled)
 33. A system for elastically compensating for wear andmisalignment, comprising: a housing having a bore; a pin located in andcoaxial with the bore of the housing; a ring located between the housingand pin in the bore of the housing, the ring comprising: a backinglayer; an expanded grid structure having a plurality of openings, formedfrom at least one of a stretched metal, expanded metal, metal alloy,plastic material and woven or nonwoven mesh, and the expanded gridstructure having a wave-like configuration with strands protruding asbulges out of a plane thereof to form a pattern of waves and bow springsto provide elastic deformation under load; a low friction layerlaminated into the openings of the expanded grid structure; and at leastone layer of adhesive for bonding the backing layer, expanded gridstructure and low friction layer together to provide elastic deformationof the ring between the housing and pin.
 34. A system according to claim1, wherein the ring comprises one of a bushing, a bearing and atolerance ring, and the at least one layer of adhesive comprises a pairof layers of melt adhesive that penetrate through the expanded gridstructure and immerse sides of the expanded grid structure to both thebacking layer and the low friction layer.
 35. A system according toclaim 1, wherein the backing layer comprises one of steel, stainlesssteel and a plain steel alloy, and has a thickness in a range of 0.01 mmto 5 mm, the expanded grid structure comprises one of stainless steel,spring steel, aluminum, bronze, thermoplastic and ceramic material. 36.A system according to claim 1, wherein the expanded grid structurecomprises a cut raw material sheet having rows that are deformed withcut strands that are twisted and form bulges in every row, and thebulges protrude out of a plane defined by the expanded grid structure.37. A system according to claim 1, wherein the ring has a 10 mmdiameter, the low friction layer compensates for 5 to 20μ of elasticdeformation, overall the ring compensate for 0.1 to 0.2 mm of elasticdeformation, and the ring provides sliding properties and tolerancecompensation for production tolerances, clearance tolerances, torquetolerances, material differences, temperature expansion and contraction,load variation, dynamic behavior, and wear between components.
 38. Asystem according to claim 1, wherein the ring provides at least one ofradial and axial elastic deformation and, when a force is applied to thepin, the expanded grid structure compresses in some areas and expands inother areas to compensate for wear and misalignment around a completecircumference of the ring.
 39. A system according to claim 1, whereinthe expanded grid structure is partially embedded into the low frictionlayer and portions of the expanded grid structure protrude from the lowfriction layer and contact the pin.
 40. A system according to claim 1,wherein a geometry of the expanded grid structure is selected andpatterned by dimensions of the openings with long way of the diamond(LWD), short way of the diamond (SWD), thickness, horizontal andvertical in-plane distance between adjacent openings, mesh openings,knot width and strand width versus LWD/SWD, and selection of a directionin which the expanded grid structure is laminated and deployed.
 41. Asystem according to claim 8, wherein the ring is made stiffer byreducing a relation of transverse mesh opening to LWD, longitudinal meshopening to SWD, increasing a strand thickness or knot width, flatteningthe expanded grid structure, increasing a thickness of a raw materialsheet, and increasing a hardness or tensile strength of the expandedgrid structure.
 42. A system according to claim 1, wherein the lowfriction layer has smooth surfaces with no additional structure, and theexpanded grid structure comprises a plurality of concave features thatare compressible under load.
 43. A system according to claim 1, whereinthe low friction layer has an undulated surface with recesses that alignwith and are complementary to concave elements of the expanded gridstructure, the recesses face away from or toward the backing layer, andboth the expanded grid structure and the recesses are compressible underload to provide elastic behavior in operation and compensate for wearand misalignment.
 44. A system according to claim 1, wherein the ringhas an original thickness, the ring deforms under load causing theexpanded grid structure and recesses in the low friction layer todeform, and the ring self-adjusts to elastically compensate for thedeformation and return the ring to the original thickness.
 45. A systemaccording to claim 12, wherein the ring has an original thickness, thering wears under load and sliding speed between the housing and pin toreduce a thickness of the low friction layer, and the expanded gridstructure self-adjusts to elastically compensate for the wear to returnthe ring to the original thickness.
 46. A system according to claim 1,wherein the low friction layer comprises a plastic compound withorganic, inorganic, metallic or plastic fillers, and has a thickness ina range of 0.01 mm to 1 mm
 47. A system according to claim 1, whereinthe low friction layer comprises a polymer comprising polyketone,polyaramid, a thermoplastic polyimide, a polyetherimide, a polyphenylenesulfide, a polyethersulfone, a polysulfone, a polyphenylene sulfone, apolyamideimide, ultra high molecular weight polyethylene, afluoropolymer, a polyamide, a polybenzimidazole, or any combinationthereof.
 48. A system according to claim 1, wherein the low frictionlayer comprises a thermoplastic material comprising a polyketone, apolyaramid, a polyimide, a polyetherimide, a polyamideimide, apolyphenylene sulfide, a polyphenylene sulfone, a fluoropolymer, apolybenzimidazole, a derivation thereof, or a combination thereof.
 49. Asystem according to claim 1, wherein the low friction layer comprises afluoropolymer comprising fluorinated ethylene propylene (FEP), PTFE,polyvinylidene fluoride (PVDF), perfluoroalkoxy (PFA), a terpolymer oftetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV),polychlorotrifluoroethylene (PCTFE), ethylene tetrafluoroethylenecopolymer (ETFE), ethylene chlorotrifluoroethylene copolymer (ECTFE), orany combination thereof.
 50. A system according to claim 1, wherein thelow friction layer comprises a polyketone, comprising polyether etherketone (PEEK), polyether ketone, polyether ketone ketone, polyetherketone ether ketone, a derivative thereof, or a combination thereof. 51.A system according to claim 1, wherein the low friction layer comprisesa lubricant comprising oil, grease, or solid lubricants such asmolybdenum disulfide, tungsten disulfide, graphite, graphene, expandedgraphite, boron nitride, talc, calcium fluoride, cerium fluoride, or anycombination thereof.
 52. A system according to claim 1, wherein the lowfriction layer comprises a ceramic or mineral comprising alumina,silica, titanium dioxide, calcium fluoride, boron nitride, mica,Wollastonite, silicon carbide, silicon nitride, zirconia, carbon black,pigments, or any combination thereof.